Coating compositions

ABSTRACT

Embodiments of the present disclosure are directed towards coating compositions comprising from 50 to 85 percent of an aqueous dispersion based on a total weight of the coating composition, an abrasion reducing composition, a solvent, a basic water composition, and a crosslinker.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Divisional Application of U.S. application Ser.No. 13/736,492, filed Jan. 8, 2013 and Published as U.S. Publication No.2014-0141268, on May 24, 2014, which claims the benefit of U.S.Provisional Application Ser. No. 61/729,014 filed Nov. 21, 2012, and isa Continuation In Part of application Ser. No. 13/039,138, filed on Mar.2, 2011 which is a Continuation In Part of application Ser. No.12/559,056 filed Sep. 14, 2009 and issued as U.S. Pat. No. 8,063,128 onNov. 22, 2011, which is a Continuation of application Ser. No.10/925,693 filed Aug. 25, 2004 and issued as U.S. Pat. No. 7,803,865 onSep. 28, 2010, which claims the benefit of Provisional Application Ser.No. 60/548,493 filed Feb. 27, 2004, and the benefit of ProvisionalApplication Ser. No. 60/497,527 filed Aug. 25, 2003, the entire contentsof which are incorporated herein by reference in its entirety.

FIELD OF DISCLOSURE

Embodiments of the present disclosure are directed to coatingcompositions, more specifically, embodiments are coating compositionsthat include an abrasion reducing composition.

BACKGROUND

Coating compositions can be applied to substrates and be cured, e.g.crosslinked, to provide a coating on the substrate. There are variouscoating compositions utilized to provide differing coatings. Coatingscan be utilized to provide protection of the substrate, provide a basefor a subsequent application such as a decorative coating, reducefriction to help provide for improved handling, and provide protectionfor contents stored within a container formed from the coated substrate,among others.

Some substrates, e.g., metal substrates, can be formed into containers,such as food and/or beverage containers. Coating compositions can beapplied to the substrates and/or to the interior and/or the exterior ofthese containers.

SUMMARY

The present disclosure provides coating compositions from comprisingfrom 50 to 85 percent of an aqueous dispersion based on a total weightof the coating composition; an abrasion reducing composition; a solvent;a basic water composition; and a crosslinker.

The present disclosure provides coated articles comprising a substrateand a coating on the substrate, wherein the coating includes the coatingcomposition.

The present disclosure provides coated articles comprising a substrateand a cured coating on the substrate, wherein the cured coating isformed by curing the coating composition.

The above summary of the present disclosure is not intended to describeeach disclosed embodiment or every implementation of the presentdisclosure. The description that follows more particularly exemplifiesillustrative embodiments. In several places throughout the application,guidance is provided through lists of examples, which examples can beused in various combinations. In each instance, the recited list servesonly as a representative group and should not be interpreted as anexclusive list.

DETAILED DESCRIPTION

Coating compositions are described herein. These coating compositionscan include an aqueous dispersion and an abrasion reducing composition.Other compositions that include an aqueous dispersion, e.g. somecompositions that are employed for beverage end can coatings, utilize alubricant. Examples of these lubricants include, but are not limited to,polytetrafluoroethylene, polydimethylsiloxane, and some hydroxyfunctional polysiloxanes. The lubricant may be utilized to provide acoefficient of friction that is desirable for some uses, including cancoatings. For example, a coating having a coefficient of friction thatis too high for a particular use may cause fouling and/or sticking ofequipment employed for that particular use. However, use of lubricantswith some other compositions can promote a non-continuous cured coatingand/or a cured coating having a coefficient of friction that is too highfor some coating applications. Surprisingly, it has been found that thecoating compositions disclosed herein, which include an abrasionreducing composition, are able to provide a continuous cured coatingwith a desirable coefficient of friction, e.g., that may becharacterized by a reduced abrasion value as compared to some othercoatings.

Embodiments of the present disclosure provide coating compositions thatcomprise an aqueous dispersion including a melt blending product of (a)a base polymer comprising at least one polyolefin, (b) a stabilizingagent, and (c) a compatiblizer.

As mentioned, embodiments of the present disclosure provide that theaqueous dispersion can include (a) a base polymer comprising at leastone polyolefin. Examples of the polyolefin include, but are not limitedto, homopolymers and copolymers (including elastomers) of one or morealpha-olefins such as ethylene, propylene, 1-butene, 3-methyl-1-butene,4-methyl-1-pentene, 3-methyl-1-pentene, 1-heptene, 1-hexene, 1-octene,1-decene, and 1-dodecene, as typically represented by polyethylene,polypropylene, poly-1-butene, poly-3-methyl-1-butene,poly-3-methyl-1l-pentene, poly-4-methyl-1-pentene, ethylene-propylenecopolymer, ethylene-1-butene copolymer, and propylene-1-butenecopolymer; copolymers (including elastomers) of an alpha-olefin with aconjugated or non-conjugated diene, as can be represented byethylene-butadiene copolymer and ethylene-ethylidene norbornenecopolymer; and polyolefins (including elastomers) such as copolymers oftwo or more alpha-olefins with a conjugated or non-conjugated diene, ascan be represented by ethylene-propylene-butadiene copolymer,ethylene-propylene-dicyclopentadiene copolymer,ethylene-propylene-1,5-hexadiene copolymer, andethylene-propylene-ethylidene norbornene copolymer; ethylene-vinylcompound copolymers such as ethylene-vinyl acetate copolymer,ethylene-vinyl alcohol copolymer, ethylene-vinyl chloride copolymer,ethylene acrylic acid or ethylene-(meth)acrylic acid copolymers, andethylene-(meth)acrylate copolymer.

According to a number of embodiments of the present disclosure, one ormore of the polyolefins may be functionalized polyolefins, such aspolypropylene or polyethylene homopolymer or copolymer where the polymerhas been modified with a hydroxyl, an amine, an aldehyde, an epoxide, anethoxylate, a carboxylic acid, an ester, an anhydride group, orcombinations thereof. Some of these functionalized polyolefins, such aspolypropylene or polyethylene homopolymers or copolymers, are available,for example, from Baker Petrolite, a subsidiary of Baker Hughes, Inc.

The polyolefin may have different molecular weights for variousapplications. For example, the polyolefin may have a molecular weight ofgreater than 800 grams/mole; for example, greater than 5,000 grams/mole;or in the alternative, greater than 50,000 grams/mole. The polyolefinmay have different crystalline melting points for various applications.For example, the polyolefin may have a crystalline melting point ofgreater than 60° C.; greater than 95° C.; greater than 100° C.; greaterthan 120° C.; greater than 130° C.

According to a number of embodiments of the present disclosure thepolyolefin may be a propylene-alpha olefin copolymer, for example,propylene-ethylene or a propylene-ethylene-butene copolymer orinterpolymer. The polyolefin may be a propylene/alpha-olefin copolymer,which is characterized as having substantially isotactic propylenesequences. “Substantially isotactic propylene sequences” means that thesequences have an isotactic triad (mm) measured by ¹³C NMR of greaterthan about 0.85; in the alternative, greater than about 0.90; in anotheralternative, greater than about 0.92; and in another alternative,greater than about 0.93. Isotactic triads are well-known in the art andare described in, for example, U.S. Pat. No. 5,504,172 and InternationalPublication No. WO 00/01745, which refer to the isotactic sequence interms of a triad unit in the copolymer molecular chain determined by ¹³CNMR spectra.

The polyolefin, e.g., the propylene/alpha-olefin copolymer, may have acrystallinity in the range of from at least 1 percent by weight (a heatof fusion of at least 2 Joules/gram) to 30 percent by weight (a heat offusion of less than 50 Joules/gram). All individual values and subrangesfrom 1 percent by weight (a heat of fusion of at least 2 Joules/gram) to30 percent by weight (a heat of fusion of less than 50 Joules/gram) areincluded herein and disclosed herein; for example, the crystallinity canbe from a lower limit of 1 percent by weight (a heat of fusion of atleast 2 Joules/gram), 2.5 percent (a heat of fusion of at least 4Joules/gram), or 3 percent (a heat of fusion of at least 5 Joules/gram)to an upper limit of 30 percent by weight (a heat of fusion of less than50 Joules/gram), 24 percent by weight (a heat of fusion of less than 40Joules/gram), 15 percent by weight (a heat of fusion of less than 24.8Joules/gram) or 7 percent by weight (a heat of fusion of less than 11Joules/gram). For example, the polyolefin may have a crystallinity inthe range of from at least 1 percent by weight (a heat of fusion of atleast 2 Joules/gram) to 24 percent by weight (a heat of fusion of lessthan 40 Joules/gram); or in the alternative, the polyolefin may have acrystallinity in the range of from at least 1 percent by weight (a heatof fusion of at least 2 Joules/gram) to 15 percent by weight (a heat offusion of less than 24.8 Joules/gram); or in the alternative, thepolyolefin may have a crystallinity in the range of from at least 1percent by weight (a heat of fusion of at least 2 Joules/gram) to 7percent by weight (a heat of fusion of less than 11 Joules/gram); or inthe alternative, the polyolefin may have a crystallinity in the range offrom at least 1 percent by weight (a heat of fusion of at least 2Joules/gram) to 5 percent by weight (a heat of fusion of less than 8.3Joules/gram). The crystallinity can be measured via a Differentialscanning calorimetry (DSC) method. Embodiments provide that thepropylene/alpha-olefin copolymer can include units derived frompropylene and polymeric units derived from one or more alpha-olefincomonomers. Examples of comonomers that can be utilized to manufacturethe propylene/alpha-olefin copolymer are C₂, and C₄ to C₁₀alpha-olefins; for example, C₂, C₄, C₆ and C₈ alpha-olefins. Thepropylene/alpha-olefin copolymer can include from 1 to 40 percent byweight of units derived from one or more alpha-olefin comonomers. Allindividual values and subranges from 1 to 40 weight percent are includedherein and disclosed herein; for example, the weight percent of unitsderived from one or more alpha-olefin comonomers can be from a lowerlimit of 1, 3, 4, 5, 7, or 9 weight percent to an upper limit of 40, 35,30, 27, 20, 15, 12, or 9 weight percent. For example, thepropylene/alpha-olefin copolymer comprises from 1 to 35 percent byweight of units derived from one or more alpha-olefin comonomers; or inthe alternative, the propylene/alpha-olefin copolymer comprises from 1to 30 percent by weight of units derived from one or more alpha-olefincomonomers; or in the alternative, the propylene/alpha-olefin copolymercomprises from 3 to 27 percent by weight of units derived from one ormore alpha-olefin comonomers; or in the alternative, thepropylene/alpha-olefin copolymer comprises from 3 to 20 percent byweight of units derived from one or more alpha-olefin comonomers; or inthe alternative, the propylene/alpha-olefin copolymer comprises from 3to 15 percent by weight of units derived from one or more alpha-olefincomonomers.

The propylene/alpha-olefin copolymer can have a molecular weightdistribution (MWD), defined as weight average molecular weight dividedby number average molecular weight (M_(w)/M_(n)) of 3.5 or less; in thealternative 3.0 or less; or in another alternative from 1.8 to 3.0. Suchpropylene/alpha-olefin copolymers are further described in U.S. Pat.Nos. 6,960,635 and 6,525,157, incorporated herein by reference. Suchpropylene/alpha-olefin copolymers are commercially available from TheDow Chemical Company, under the tradename VERSIFY™, or from ExxonMobilChemical Company, under the tradename VISTAMAXX™.

In a number of embodiments of the present disclosure, thepropylene/alpha-olefin copolymers are further characterized as including(A) between 60 and less than 100, preferably between 80 and 99 and morepreferably between 85 and 99, weight percent units derived frompropylene, and (B) between greater than zero and 40, preferably between1 and 20, more preferably between 4 and 16 and even more preferablybetween 4 and 15, weight percent units derived from at least one ofethylene and/or a C₄₋₁₀ α-olefin; and containing an average of at least0.001, preferably an average of at least 0.005 and more preferably anaverage of at least 0.01, long chain branches/1000 total carbons,wherein the term long chain branch, as used herein, refers to a chainlength of at least one carbon more than a short chain branch, and shortchain branch, as used herein, refers to a chain length of two carbonsless than the number of carbons in the comonomer. For example, apropylene/1-octene interpolymer has backbones with long chain branchesof at least seven carbons in length, but these backbones also have shortchain branches of only six carbons in length. In a number ofembodiments, the maximum number of long chain branches does not exceed 3long chain branches/1000 total carbons. Such propylene/alpha-olefincopolymers are further described in U.S. Provisional Patent ApplicationNo. 60/988,999 and International Patent Application No. PCT/US08/082599,each of which is incorporated herein by reference.

Embodiments of the present disclosure provide that the aqueousdispersion can include (b) a stabilizing agent. The stabilizing agentcan help to promote formation of a stable dispersion, e.g., the aqueousdispersion.

Embodiments provide that the stabilizing agent include a surfactant, apolymer, or a combination thereof. For example, the stabilizing agentcan be a polar polymer, e.g., including a polar group as either acomonomer or grafted monomer. In some embodiments, the stabilizing agentcan include one or more polar polyolefins, e.g., having a polar group aseither a comonomer or grafted monomer.

Examples of polymeric stabilizing agents include, but are not limitedto, ethylene-acrylic acid and ethylene-methacrylic acid copolymers, suchas those available under the trademarks PRIMACOR™, commerciallyavailable from The Dow Chemical Company, NUCREL™, commercially availablefrom E.I. DuPont de Nemours, and ESCOR™, commercially available fromExxonMobil Chemical Company and described in U.S. Pat. Nos. 4,599,392,4,988,781, and 5,938,437, each of which is incorporated herein byreference in its entirety. Other examples of polymeric stabilizingagents include, but are not limited to, ethylene ethyl acrylatecopolymer, ethylene methyl methacrylate, ethylene butyl acrylate, andcombinations thereof. Other ethylene-carboxylic acid copolymer may alsobe used. Those having ordinary skill in the art will recognize that anumber of other useful polymers may also be used.

In some embodiments, the stabilizing agent can include a functionalizedpolyolefin, e.g., a polypropylene or polyethylene homopolymer orcopolymer in which the polymer has been modified with a hydroxyl, anamine, an aldehyde, an epoxide, an ethoxylate, a carboxylic acid, anester, an anhydride group, or combinations thereof. Some offunctionalized polyolefins such as polypropylene or polyethylenehomopolymers and copolymers are available, for example, from BakerPetrolite, a subsidiary of Baker Hughes, Inc.

In some embodiments, the stabilizing agent can include long chain fattyacids, fatty acid salts, or fatty acid alkyl esters having from 12 to 60carbon atoms. In other embodiments, the long chain fatty acid or fattyacid salt may have from 12 to 40 carbon atoms.

As mentioned, the stabilizing agent can include a surfactant. Examplesof the surfactant include, but are not limited to, cationic surfactants,anionic surfactants, non-ionic surfactants, and combinations thereof.Examples of anionic surfactants include, but are not limited to,sulfonates, carboxylates, and phosphates. Examples of cationicsurfactants include, but are not limited to, quaternary amines. Examplesof non-ionic surfactants include, but are not limited to, blockcopolymers containing ethylene oxide and silicone surfactants.

The stabilizing agent can include an external surfactant and/or aninternal surfactant, for example. External surfactants are surfactantsthat do not become chemically reacted into the polyolefin duringdispersion preparation. Examples of external surfactants include, butare not limited to, salts of dodecyl benzene sulfonic acid and laurylsulfonic acid salt. Internal surfactants are surfactants that do becomechemically reacted into the polyolefin during dispersion preparation.

Examples of commercially available surfactants include, but are notlimited to: OP-100 (a sodium stearate), OPK-1000 (a potassium stearate),and OPK-181 (a potassium oleate), each available from RTD Hallstar;UNICID 350, available from Baker Petrolite; DISPONIL FES 77-IS andDISPONIL TA-430, each available from Cognis; RHODAPEX CO-436, SOPROPHOR4D384, 3D-33, and 796/P, RHODACAL BX-78 and LDS-22, RHODAFAC RE-610, andRM-710, and SUPRAGIL MNS/90, each available from Rhodia; and TRITONQS-15, TRITON W-30, DOWFAX 2A1, DOWFAX 3B2, DOWFAX 8390, DOWFAX C6L,TRITON X-200, TRITON XN-45S, TRITON H-55, TRITON GR-5M, TRITON BG-10,and TRITON CG-110, each available from The Dow Chemical Company,Midland, Mich.

The stabilizing agent can include solution or suspension polymers, e.g.,polymers of ethylenically unsaturated monomers such as acrylic and/ormethacrylic acid and their (C₁-C₃₀) esters or amides;acrylamide/methacrylamide and their N-substituted derivatives;acrylonitrile; styrene and substituted styrene derivatives.

The stabilizing agent can include a polymeric stabilizing agent.Examples of polymeric stabilizing agents include, but are not limitedto, amphiphilic copolymer compositions, the copolymer including thereaction product of from 5 weight percent to 95 weight percent of one ormore hydrophilic monomers and from 5 weight percent to 95 weight percentof one or more copolymerizable ethylenically unsaturated hydrophobicmonomers. These materials are water soluble and/or emulsifiable, forexample upon neutralization and can act as colloidal stabilizers.

Examples of nonionic monomers useful for production of amphiphiliccopolymer compositions, include, but are not limited to, acrylamide,methacrylamide, N,N-dimethylacrylamide, N,N-diethylacrylamide,N-isopropylacrylamide, N-vinylformamide, N-vinylmethylacetamide, N-vinylpyrrolidone, hydroxyethyl methacrylate, hydroxyethyl acrylate,hydroxypropyl acrylate, hydroxypropyl methacrylate, t-butylacrylamide, Nmethylolacrylamide, alkyl(meth)acrylates such as methyl(meth)acrylate,butyl acrylate and ethylacrylate, vinyl monomers such as ethylene,styrene, divinylbenzene, di-isobutylethylene, vinyl acetate and N-vinylpyrrolidone, and allyl monomers such as allyl (meth)acrylate.

Examples of monomers useful for production of amphiphilic copolymercompositions include, but are not limited to, unsaturated amidefunctionalized monomers such as acrylamide, methacrylamide,N,N-dimethylacrylamide, N,N-diethylacrylamide, N-isopropylacrylamide,N-vinylformamide, N-vinylmethylacetamide, N-vinyl pyrrolidone,t-butylacrylamide, and N-methylolacrylamide; monomers containingquaternary ammonium salts such as tributylammonium ethyl(meth)acrylatechloride, diallyldimethylammonium chloride,methylacrylamidopropyltrimethylammonium chloride,acrylamidopropyltrimethylammonium chloride, polyquaternium-11 andpolyquaternium-4; and amine functionalized monomers such asvinylimidazole.

“Anionic” or “acid-containing monomer” useful for production ofamphiphilic copolymer compositions include, but are not limited to,ethylenically unsaturated monomers containing carboxylic acid,phosphonic acid, phosphinic acid, sulfinic acid, sulfonic acid groups,and anhydrides that are subsequently hydrolyzed. Suitable examplesinclude (meth)acrylic acid, maleic acid, fumaric acid, itaconic acid,vinyl phosphonic acid, phosphoethyl (meth)acrylate, and vinylsulfonicacid.

According to a number of embodiments, one or more of the stabilizingagents may be based on resins such as polyester, epoxy resins, polyamideresins, which might be reacted with acrylic resins or acrylic monomersto form polyester acrylate, polyamide acrylates epoxy resin acrylates.

Polyester resins useful for producing stabilizing agents may be obtainedin accordance with conventional procedures well known to those ofordinary skill in the art by reacting, for example, a polybasic acidthat contains at least two carboxyl groups per polybasic acid molecule(e.g. an at least dibasic polycarboxylic acid) with a polyhydric alcoholthat contains at least two hydroxyl groups in the polyhydric alcohol(e.g., at least dihydric alcohol) in presence of a conventionalesterification catalyst at an elevated temperature with or withoutsolvent present. Alternatively alkyl esters of the polycarboxylic acidsor anhydrides of polycarboxylic acids can be reacted in presence of aconventional esterification catalyst at an elevated temperature. One ormore polymerizable double bonds may be included into the polyester byemploying a polybasic acid that contains polymerizable double bondsand/or a polyhydric alcohol that contains polymerizable double bonds.

The stabilizing agent may include a polyester acrylate. Polyesteracrylates may be formed via in-situ polymerization of copolymerizableethylenically unsaturated monomers in presence of polyesters. Examplesinclude ethylenically unsaturated mono- or polyfunctional acids,ethylenically unsaturated mono- or polyfunctional acid esters, amides,nitriles as well as vinyl monomers and vinyl ester with a polyester inor without presence of a reaction fluid. Polyester acrylates in solventscan be dried according to suitable methods known to those of ordinaryskill in the art.

The stabilizing agent may include an epoxy resin. Epoxy resins may beobtained in accordance with conventional procedures well known to thoseof ordinary skill in the art, e.g., by reacting a polyepoxide with asuitable polynucleophile. Suitable epoxides include, but are not limitedto, glycidyl ethers, and other epoxy group containing molecules.Suitable polynucleophiles include, but are not limited to, polyhydricphenols, and poly phenols, polythiols, aliphatic polyalcohols orpolybasic acids or polyamines. Examples of epoxies include, but are notlimited to, glycidyl ether that contains at least two glycidyl ethergroups per polyglycidyl ether molecule (e.g. an at least diglycidylether) with a polyhydric phenol that contains at least two hydroxylgroups in the polyhydric polyphenol (e.g., at least dihydric phenol or adiphenol) in presence of a conventional catalyst at an elevatedtemperature with or without solvent present. Other epoxy resins may beobtained in accordance with conventional procedures well known to thoseof ordinary skill in the art by reacting, for example, a polyglycidylether that contains at least two glycidyl ether groups per polyglycidylether molecule (e.g. an at least diglycidyl ether) with a polybasic acidthat contains at least two carboxyl groups per polybasic acid molecule(e.g. an at least dibasic polycarboxylic acid) in presence of aconventional catalyst at an elevated temperature with or without solventpresent.

The stabilizing agent may include an epoxy acrylate. The epoxy acrylatesmay be formed via in-situ polymerization of copolymerizableethylenically unsaturated monomers in presence of epoxy resins. Examplesinclude, but are not limited to, ethylenically unsaturated mono- orpolyfunctional acids, ethylenically unsaturated mono- or polyfunctionalacid esters, amides, nitriles as well as vinyl monomers and vinyl esterwith an epoxy resins in or without presence of a reaction fluid.Alternatively a polymeric acid functional acrylic resin can be reactedwith an epoxy resin in the presence of a suitable catalyst to form epoxyacrylate. Epoxy acrylates in solvents can be dried according to suitablemethods known to those of ordinary skill in the art.

Embodiments of the present disclosure provide that the aqueousdispersion can include (c) a compatiblizer. The compatiblizer can helpin formation of the aqueous dispersion, e.g., help provide a moreuniform dispersion, and/or improve properties of a cured coatingcomposition. Compatiblizers may also be referred to as coupling agents.

The compatiblizer can include a modified, e.g., functionalized, polymerand optionally a low molecular weight compound having reactive polargroups. Examples of the compatiblizer include, but are not limited tomodified olefin polymers. The modified olefin polymers can include graftcopolymers and/or block copolymers, such as propylene-maleic anhydridegraft copolymer. Examples of groups that can modify the polymer include,but are not limited to, acid anhydrides, carboxylic acids, carboxylicacid derivatives, primary and secondary amines, hydroxyl compounds,oxazoline and epoxides, and ionic compounds, and combinations thereof.Specific examples of the groups that can modify the polymer include, butare not limited to, unsaturated cyclic anhydrides and their aliphaticdiesters, and the diacid derivatives. For example, maleic anhydride andcompounds selected from C₁-C₁₀ linear and branched dialkyl maleates,C₁-C₁₀ linear and branched dialkyl fumarates, itaconic anhydride, C₁-C₁₀linear and branched itaconic acid dialkyl esters, maleic acid, fumaricacid, itaconic acid, and combinations thereof. Commercially availableexamples of compatiblizers include, but are not limited to, polymersavailable, under the trade names LICOCENE® from Clariant Corporation,such as LICOCENE® 6452, which is a propylene-maleic anhydride graftcopolymer; EXXELOR™ from ExxonMobil Chemical Company; and Epolene fromWestlake Chemical Company.

The aqueous dispersion includes a fluid medium, e.g., water. The aqueousdispersion can comprise 30 weight percent to 85 weight percent of waterbased on a total weight of the aqueous dispersion; for example theaqueous dispersion can comprise 35 weight percent to 80 weight percent,40 weight percent to 75 weight percent, or 45 weight percent to 70weight percent of water based on a total weight of the aqueousdispersion.

Accordingly, the aqueous dispersion can comprise a solids content thatis 15 weight percent to 70 weight percent based on the total weight ofthe aqueous dispersion; for example the aqueous dispersion can havesolids content that is 20 weight percent to 68 weight percent, 25 weightpercent to 65 weight percent, or 30 weight percent to 60 weight percentbased on the total weight of the aqueous dispersion.

The solids content of the aqueous dispersion can comprise 50 to 85percent by weight of the base polymer based on a total weight of thesolids content; for example the solids content of the aqueous dispersioncan comprise 55 to 80 percent, or 60 to 80 percent by weight of the basepolymer based on the total weight of the solids content.

The solids content of the aqueous dispersion can comprise 10 to 35percent by weight of the stabilizing agent based on the total weight ofthe solids content; for example the solids content of the aqueousdispersion can comprise 12 to 33 percent, or 15 to 30 percent by weightof the stabilizing agent based on the total weight of the solidscontent.

The solids content of the aqueous dispersion can comprise 2 to 15percent by weight of the compatiblizer based on the total weight of thesolids content; for example the solids content of the aqueous dispersioncan comprise 3 to 13 percent, or 5 to 10 percent by weight of thecompatiblizer based on the total weight of the solids content.

The aqueous dispersion can be from 50 to 85 weight percent of thecoating composition based on a total weight of the coating composition;for example the aqueous dispersion can be 55 to 80 weight percent, or 60to 75 weight percent of the coating composition based on the totalweight of the coating composition.

According to a number of embodiments of the present disclosure, theaqueous dispersion can comprise a base, e.g., such that the aqueousdispersion has a pH in a range from 8 to 11. All individual values andsubranges from 8 to 11 are included herein and disclosed herein; forexample, the aqueous dispersion can have a pH from a lower limit of 8,8.1, 8.2, or 8.3 to an upper limit of 11, 10.9, 10.8, or 10.7. Forexample, the aqueous dispersion can have a pH from 8 to 11, 8.1 to 10.9,8.2 to 10.8, or 8.3 to 10.7. Examples of the base include, but are notlimited to, hydroxides, carbonates, amines, and combinations thereof.Examples of hydroxides include, but are not limited to, ammoniumhydroxide, potassium hydroxide, lithium hydroxide, and sodium hydroxide.Examples of carbonates include, but are not limited to sodium carbonate,sodium bicarbonate, potassium carbonate, and calcium carbonate. Examplesof amines include, but are not limited to monoethanolamine,diethanolamine, triethanolamine, ammonia, monomethylamine,dimethylamine, trimethylamine, 2-amino-2-methyl-1-propanol,triisopropanolamine, diisopropanolamine, N,N-dimethylethanolamine,mono-n-propylamine, dimethyl-n propylamine, N-methanol amine,N-aminoethylethanolamine, N-methyldiethanolamine, monoisopropanolamine,N,N-dimethyl propanolamine, 2-amino-2-methyl-1-propanol,tris(hydroxymethyl)-aminomethane,N,N,N′N′-tetrakis(2-hydroxylpropyl)ethylenediamine, 1,2-diaminopropane,2-amino-2-hydroxymethyl-1,3-propanediol,N,N′-ethylenebis[bis(2-hydroxypropyl)amine]toluene-p-sulphonate, andcombinations thereof.

The aqueous dispersions can be formed by various processes recognized bythose having skill in the art. Embodiments provide that one or more basepolymers, one or more stabilizing agents, and one or more compatiblizersare melt-kneaded in an extruder, e.g. via a BLUEWAVE™ process, to form amelt blending product. Water and a neutralizing agent, such as ammonia,potassium hydroxide, or a combination thereof can be utilized to form anaqueous dispersion, e.g., an aqueous polyolefin dispersion. In a numberof embodiments, the aqueous dispersion is first diluted to contain about1 to about 3% by weight water and then, subsequently, further diluted tocomprise greater than about 25% by weight water.

Various melt-kneading processes known in the art may be used. In someembodiments, a kneader, a BANBURY® mixer, single-screw extruder, or amulti-screw extruder, e.g. a twin screw extruder, may be utilized. Aprocess for producing the aqueous dispersions in accordance with thepresent disclosure is not particularly limited. For example, anextruder, in certain embodiments, for example, a twin screw extruder, iscoupled to a back pressure regulator, melt pump, or gear pump.Embodiments also provide a base reservoir and an initial waterreservoir, each of which includes a pump. Desired amounts of base andinitial water can be provided from the base reservoir and the initialwater reservoir, respectively. Various suitable pumps may be used, butin some embodiments, for example, a pump that provides a flow of about150 cc/min at a pressure of 240 bar can be used to provide the base andthe initial water to the extruder. In other embodiments, a liquidinjection pump provides a flow of 300 cc/min at 200 bar or 600 cc/min at133 bar. In some embodiments, the base and initial water are preheatedin a preheater. For example, in a number of embodiments, one or morebase polymers, e.g., in the form of pellets, powder, or flakes, can befed from the feeder to an inlet of an extruder where the polymers aremelted. In some embodiments, a dispersing agent can be added to the oneor more base polymers through and along with the resin and in otherembodiments, the dispersing agent can be provided separately to theextruder. The melted polymers can then be delivered from the mix andconvey zone to an emulsification zone of the extruder where an initialamount of water and/or base from the water and base reservoirs can beadded through an inlet. In some embodiments, a dispersing agent may beadded additionally or exclusively to the water stream. In someembodiments, further dilution water may be added via water inlet from awater reservoir to a dilution and cooling zone of the extruder. Theaqueous dispersion can be diluted, e.g., to at least 30 weight percentwater, in the cooling zone. Further dilution may occur a number of timesuntil the desired dilution level is achieved. In some embodiments, wateris not added into the twin screw extruder but rather to a streamcontaining the melt product after the melt product has exited from theextruder. In this manner, steam pressure build-up in the extruder iseliminated and the aqueous dispersion is formed in a secondary mixingdevice such as a rotor stator mixer.

In one or more embodiments, a process for producing the aqueousdispersion comprises the steps of (1) selecting one or more basepolymers; (2) selecting one or more stabilizing agents; (3) selectingone or more compatiblizers; (4) selecting a liquid media comprisingwater; (5) optionally selecting one or more neutralizing agents; (6)melt-blending the one or more base polymers, one or more stabilizingagents, and the one or more compatablizers in the presence of water andoptionally one or more neutralizing agents; (6) thereby forming anemulsified mixture; (7) contacting the emulsified mixture withadditional dilution water while optionally removing heat therefrom; (8)thereby forming solid particles dispersed in the water; and (9) therebyforming the aqueous dispersion.

The aqueous dispersion can have an average volume particle size diameterin the range of from 400 to 1500 nanometers (nm). All individual valuesand subranges from 400 to 1500 nm are included herein and disclosedherein; for example, the aqueous dispersion can have an average volumeparticle size diameter from a lower limit of 400, 425, or 450 nm to anupper limit of 1500, 1475, or 1450 nm. For example, the aqueousdispersion can have an average volume particle size diameter from 400 to1500 nm, 425 to 1475 nm, or 450 to 1450 nm.

Embodiments of the present disclosure provide that the coatingcompositions disclosed herein can be formed by combining the aqueousdispersion with other components to form the coating compositions. Theaqueous dispersion and other components of the coating compositions,discussed further herein, can be combined by various processes. Forexample, the aqueous dispersion and other components of the coatingcompositions can be mixed manually, by utilizing a mixer such staticmixer, also referred as in-line mixers, and/or by utilizing an agitatedvessel, such as an agitated tank to form the coating compositionsdisclosed herein, among other processes.

As mentioned, the coating compositions disclosed herein comprise anabrasion reducing composition. Embodiments provide that the abrasionreducing composition comprises a wax that is from 0.01 weight percent to1.5 weight percent of the coating composition based on the total weightof the coating composition. All individual values and subranges from andincluding 0.01 weight percent to 1.5 weight percent of the coatingcomposition based on the total weight of the coating composition areincluded herein and disclosed herein; for example, the wax may be in arange with a lower limit of 0.01, 0.10, or 0.25 weight percent of thecoating composition based on the total weight of the coating compositionto an upper limit of 1.5 weight percent, 1.25 weight percent, or 1.0weight percent of the coating composition based on the total weight ofthe coating composition. The wax may be utilized neat, e.g., the wax maybe directly added to the coating compositions, or as component of ablend, such as a mixture or a dispersion that may be added to thecoating compositions, for example. A number of embodiments of thepresent disclosure provide that the aqueous dispersion can comprise thewax, e.g., the wax, or a portion of the wax, can be a component of theaqueous dispersion.

Embodiments of the present disclosure provide that the wax can compriseFischer-Tropsch wax, carnauba wax, or a combination thereof.Fischer-Tropsch wax is synthetic wax that is generated from the knownFischer-Tropsch synthesis in which either coal or natural gas derivedcarbon monoxide is combined with hydrogen to produce hydrocarbons,followed by polymerization to produce the Fischer-Tropsch wax. TheFischer-Tropsch wax can have a molar mass of from 300 to 2000grams/mole. All individual values and subranges from and including 300to 2000 grams/mole are included herein and disclosed herein; forexample, the Fischer-Tropsch wax may have molar mass in a range with alower limit of 300, 325, or 350 grams/mole to an upper limit of 2000,1950, or 1900 grams/mole. The Fischer-Tropsch wax can have a meltingpoint from 90° C. to 110° C. All individual values and subranges fromand including 90° C. to 110° C. are included herein and disclosedherein; for example, the Fischer-Tropsch wax may have melting point in arange with a lower limit of 90° C., 91° C., or 92° C. to an upper limitof 110° C., 109° C. or 108° C. An example of commercially availableFischer-Tropsch wax includes SLIP-AYD® SL 404, available from Elementis.

Carnauba wax is a natural vegetable wax. An example of commerciallyavailable carnauba wax includes AQUACER® 1547, available from BYK.

Embodiments of the present disclosure provide that the abrasion reducingcomposition comprises a hydroxy functional polysiloxane. The hydroxyfunctional polysiloxane can be from 0.01 weight percent to 0.10 weightpercent of the coating composition based on the total weight of thecoating composition. All individual values and subranges from andincluding 0.01 weight percent to 0.10 weight percent of the coatingcomposition based on the total weight of the coating composition areincluded herein and disclosed herein; for example, the hydroxyfunctional polysiloxane may be in a range with a lower limit of 0.01,0.02, or 0.03 weight percent of the coating composition based on thetotal weight of the coating composition to an upper limit of 0.10 weightpercent, 0.09 weight percent, or 0.08 weight percent of the coatingcomposition based on the total weight of the coating composition.

The hydroxy functional polysiloxane can have a hydroxyl equivalentweight of 500 to 2000 grams per hydroxyl equivalent. All individualvalues and subranges from and including 500 grams per hydroxylequivalent to 2000 grams per hydroxyl equivalent are included herein anddisclosed herein; for example, the hydroxy functional polysiloxane mayhave a hydroxyl equivalent weight in a range with a lower limit of 500,750 or 1000 grams per hydroxyl equivalent to an upper limit of 2000,1750 or 1500 grams per hydroxyl equivalent.

The hydroxy functional polysiloxane can comprise a polyether modifiedhydroxy functional polysiloxane, a polyester modified hydroxy functionalpolysiloxane, and/or a polyether-polyester modified hydroxy functionalpolysiloxane.

A number of embodiments of the present disclosure provide that thepolyether modified hydroxy functional polysiloxane can be represented bythe following formula I:

where each R group is independently C₁-C₂₀ alkyl group or a C₁-C₂₀ arylgroup; R¹ is a C₁-C₂₀ bridging group; R² is ((C(R⁴)(R⁵))_(x); R³ is((C(R⁶)(R⁷))_(z); R⁴, R⁵, R⁶, and R⁷ each are independently selectedfrom hydrogen and a C₁-C₆ alkyl group; m is from 1 to 25; n is from 1 to20; y is from 1 to 500; x is from 1 to 4; and z is from 0 to 4. Examplesof the C₁-C₂₀ bridging group include, but are not limited to, methyleneand higher alkylene groups.

The polyether modified hydroxy functional polysiloxane can comprise alinear or branched polysiloxane that is modified by one more polyethergroups attached through silicon-carbon bonds or silicone-oxygen-carbonbonds, for example. Examples of the polyether include polyethyleneoxide, polypropylene oxide, and combinations thereof. Examples of thepolyether modified hydroxy functional polysiloxane include, but are notlimited to, those commercially available from Evonik under the productname TEGO® Glide 440 polyether-modified polysiloxane, TEGO® Glide 410polyether-modified polysiloxane, and TEGO® Glide 425 polyether-modifiedpolysiloxane, among others.

A number of embodiments of the present disclosure provide that thepolyester modified hydroxy functional polysiloxane can be represented bythe following formula II:

where each R group is independently C₁-C₂₀ alkyl group or a C₁-C₂₀ arylgroup; R¹ is a C₁-C₂₀ bridging group; R² and R³ are each independently aC₂-C₆ alkylene or a C₂-C₆ benzene-diyl; m is form 1 to 25; n is from 1to 20; and y is from 1 to 500. Examples of the C₁-C₂₀ bridging groupinclude, but are not limited to, methylene and higher alkylene groups.Examples of the C₂-C₆ benzene-diyl include, but are not limited to,benzene-1,2-diyl, benzene-1,3-diyl, and benzene-1,4-diyl.

The polyester modified hydroxy functional polysiloxane can comprise alinear or branched polysiloxane that is modified by one more polyestergroups attached through silicon-carbon bonds or silicone-oxygen-carbonbonds, for example. Examples of the polyester include polylactic acid,polycaprolactone, and combinations thereof. Examples of the polyethermodified hydroxy functional polysiloxane include, but are not limitedto, those commercially available from BYK under the product nameBYK®-370, among others.

A number of embodiments of the present disclosure provide that thepolyether-polyester modified hydroxy functional polysiloxane can berepresented by the following formula III:

A where each R group is independently C₁-C₂₀ alkyl group or a C₁-C₂₀aryl group; R¹ is a C₁-C₂₀ bridging group; R² is ((C(R⁴)(R⁵))_(x); R³ is((C(R⁶)(R⁷))_(z); R⁴, R⁵, R⁶, and R⁷ each are independently selectedfrom hydrogen and a C₁-C₆ alkyl group; R⁸ is a C₁-C₂₀ bridging group; R⁹and R¹⁰ are each independently a C₂-C₆ alkylene or a C₂-C₆ benzene-diyl;m is from 1 to 25; n is from 1 to 20; o is from 1 to 25; p is from 1 to20; x is from 1 to 4; y is from 1 to 500; and z is from 0 to 4. Examplesof the C₁-C₂₀ bridging group include, but are not limited to, methyleneand higher alkylene groups.

The polyether-polyester modified hydroxy functional polysiloxane cancomprise a linear or branched polysiloxane that is modified by one morepolyester groups and one or more polyether groups attached throughsilicon-carbon bonds or silicone-oxygen-carbon bonds, for example.Examples of the polyether include polyethylene oxide, polypropyleneoxide, and combinations thereof. Examples of the polyester includepolylactic acid, polycaprolactone, and combinations thereof. Examples ofthe polyether-polyester modified hydroxy functional polysiloxaneinclude, but are not limited to, those commercially available from BYKunder the product name BYK®-375, among others.

Embodiments of the present disclosure provide that the coatingcomposition comprises a solvent. The solvent can be from 3 weightpercent to 20 weight percent of the coating composition based on thetotal weight of the coating composition. All individual values andsubranges from 3 weight percent to 20 weight percent of the coatingcomposition based on the total weight of the coating composition areincluded herein and disclosed herein; for example, the solvent can befrom a lower limit of 3, 4, or 5 weight percent of the coatingcomposition based on the total weight of the coating composition to anupper limit of 20, 19, or 18 weight percent of the coating compositionbased on the total weight of the coating composition. For example, thesolvent can be from 3 to 20, 4 to 19, or 5 to 18 weight percent of thecoating composition based on the total weight of the coatingcomposition. Examples of the solvent include, but are not limited to,glycol ethers, alcohols, aromatics, e.g. aromatic hydrocarbons, whitespirit, branched ketones, esters, and combinations thereof. According toone or more embodiments, the solvent is selected for the group ofethylene glycol, diethylene glycol monoethyl ether, dipropylene glycoldimethyl ether, propylene glycol methyl ether, ethanol, dipropyleneglycol methyl ether, and combinations thereof.

The coating compositions disclosed herein can comprise a basic watercomposition. The basic water composition includes a base. Examples ofthe base include, but are not limited to, those bases discussed herein.

The basic water composition can comprise from 90 to 99.9 percent byweight of water based on a total weight of the basic water composition.All individual values and subranges from 90 to 99.99 percent by weightof water based on a total weight of the basic water composition areincluded herein and disclosed herein; for example, the percent by weightof water based on a total weight of the basic water composition can befrom a lower limit of 90, 90.5, 91, or 93 to an upper limit of 99.99,99.9, 99, or 98 percent. For example, the basic water composition cancomprise from 90 to 99.99, 90.5 to 99.9, 91 to 99, or 93 to 98 percentby weight of water based on a total weight of the basic watercomposition. The basic water composition can comprise from 0.01 to 10percent by weight of a base based on the total weight of the basic watercomposition. All individual values and subranges from 0.01 to 10 percentby weight of the base based on a total weight of the basic watercomposition are included herein and disclosed herein; for example, thepercent by weight of the base based on a total weight of the basic watercomposition can be from a lower limit of 0.01, 0.1, 1, or 2 to an upperlimit of 10, 9.5, 9, or 7 percent. For example, the basic watercomposition can comprise from 0.01 to 10, 0.1 to 9.5, 1 to 9, or 2 to 7percent by weight of the base based on a total weight of the basic watercomposition.

The coating compositions disclosed herein can have a pH in a range from8 to 11. All individual values and subranges from 8 to 11 are includedherein and disclosed herein; for example, the coating composition canhave a pH from a lower limit of 8, 8.1, 8.2, or 8.3 to an upper limit of11, 10.9, 10.8, or 10.7. For example, the coating composition can have apH from 8 to 11, 8.1 to 10.9, 8.2 to 10.8, or 8.3 to 10.7.

The coating compositions disclosed herein can comprise a crosslinker.The crosslinker can be from 0.01 to 40 weight percent of the coatingcomposition based on the total weight of the coating composition. Allindividual values and subranges from 0.01 to 40 weight percent areincluded herein and disclosed herein; for example, the crosslinker canbe from a lower limit of 0.01, 0.02, or 0.1, to an upper limit of 40,30, or 20 weight percent of the coating composition based on the totalweight of the coating composition. For example, the crosslinker can from0.01 to 40 weight percent, 0.02 to 30 weight percent, or 0.1 to 20weight percent of the coating composition based on the total weight ofthe coating composition.

Embodiments of the present disclosure provide that the crosslinker maybe a compound, which reacts with a reactive functional group containedin the coating composition; thereby facilitating the crosslinkingbetween such functional groups. Such functional groups can be present incomponents of the aqueous dispersion, for example in (a) the basepolymer, (b) the polymeric stabilizing agent, and/or (c) thecompatiblizer. For example, reactive functional groups include, but arenot limited to, acid groups such as carboxylic acid groups, free or inthe neutralized form, or any functional groups having another activehydrogen by another component such as alcohol groups, amino groups, orthe like.

Crosslinkable functional groups in the crosslinker are groups capable ofreacting with the reactive functional groups of the coatingcompositions. For example, a carbodiimide group, an oxazoline group, anisocyanate group, a hydroxyalkylamide group, an epoxy group, a methylolgroup, an aldehyde group, an acid anhydride group, a hydroxy group, anaziridinyl group, and/or a silane group can be for the crosslinker.

Another possibility of crosslinking acid functional groups is by use ofmultivalent metal ions by reaction of the aforementioned acid groupswith a multivalent metal ion containing substance, such as zinc oxide.Carboxylic acids could also be crosslinked in reactions withmultifunctional olefinic unsaturated substances under catalysis of astrong acid. Multifunctional carbonates could also react with carboxylicacids to give ester linkages with liberation of carbon dioxide. Also,polyolefinic materials may be crosslinked via free radical crosslinking,initiated by addition of peroxides or via radiation, e.g., electronbeam.

According to a number of embodiments the crosslinker comprisesphenol-formaldehyde resins; hydroxyalkylamide resins; amino-formaldehyderesins including, but not limited to, urea-formaldehyde resins, melamineformaldehyde resins, benzoguanamine formaldehyde resins, anhydrideresins; epoxy group containing resins, including, but not limited, toepoxy resins, epoxy group containing polyester or acrylic resins andblocked isocyanate resins, and combinations of two or more thereof,provided that the combinations of such crosslinkers is compatible.

The crosslinker may be a waterdispersed, waterdispersible, orwater-soluble substance. According to a number of embodiments, examplesof the crosslinker include, but are not limited to, an aqueous monomericor polymeric substance, which contains two or more oxazoline groups,carbodiimide groups, hydroxyalkylamide groups, epoxy groups, isocyanategroups, methylol groups etc. or several of these per molecule.

An example of an oxazoline crosslinker is an aqueous polymer having twoor more oxazoline groups in its molecules, which can be obtained bypolymerizing an oxazoline group-containing monomer and, as required, anethylenic unsaturated monomer. Alternatively an oxazoline crosslinkercan also be obtained by reaction between a nitrile group and anaminoethanol group, dehydration of a hydroxylalkylamide group and thelike.

Crosslinkers having two or more carbodiimide groups can be produced fromdiisocyanate compounds by a condensation reaction accompanied bydecarboxylation reaction of a diisocyanate compound. Examples of thediisocyanate compound include, but are not limited to, 1,5-naphthylenediisocyanate, 4,4′-diphenylmethane diisocyanate,4,4′-diphenyldimethylmethane diisocyanate, 1,4-phenylene diisocyanate,2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, hexanemethylenediisocyanate, cyclohexane-1,4-diisocyanate, xylylene diisocyanate,isophorone diisocyanate, dicyclohexylmethane-4,4′-diisocyanate,methylcyclohexane diisocyanate, and tetramethylxylylene diisocyanate andthe like. These compounds may also be used as mixtures. Monofunctionalisocyanates may be included, e.g., to control the resin molecular chainlength, such as phenyl isocyanate, tolyl isocyanate,cyclohexylisocyanate, dimethylphenyl isocyanate, butylisocyanate, andnaphthyl isocyanate are useful. Diisocyanate substances may be partiallyreacted with aliphatic compounds, alicyclic compounds, or aromaticcompounds having a hydroxyl group, an imino group, an amino group, acarboxyl group, a mercapto group, an epoxy group, and the like. In thecondensation reaction accompanied by decarboxylation of a diisocyanatecompound, a carbodiimidization catalyst can be used. Usable as such acatalyst are, for example, phospholene oxides such as1-phenyl-2-phospholene-1-oxide, 3-methyl-2-phospholene-1-oxide,1-ethyl-2-phospholene-1-oxide, and 3-phospholene isomers thereof.

To convert a carbodiimide group-containing polymer into an aqueouspolymer, a hydrophilic segment can be provided in the molecularstructure of the carbodiimide group-containing polymer. For example, anaqueous polymer containing a carbodiimide group can be obtained byproviding a hydrophilic segment having a functional group which hasreactivity with an isocyanate group. Usable as the hydrophilic segmentare: quaternary ammonium salts of dialkylamino alkylamine (e.g.,quaternary ammonium salts of 2-dimethylaminoethanol); quaternary saltsof dialkylamino alkylamine(e.g., 3-dimethylamino-n-propylamine); alkylsulfonic acid salts having at least one reactive hydroxyl group (e.g.,sodiumhydroxypropanesulfonate); a mixture of polyethylene oxide orpolyethylene oxide, whose terminal is capped with an alkoxy group, and apolypropylene oxide (e.g., polyethylene oxide whose terminal position iscapped with a methoxygroup or an ethoxy group).

The crosslinker, e.g. an aqueous crosslinker, may contain an epoxygroup; examples include, but are not limited to, sorbitol polyglycidylether, glycerol triglycidyl ether, polyglycerol polyglycidyl ether,trimethylolpropane triglycidyl ether, poly(ethyleneglycol) diglycidylether, poly(propyleneglycol) diglycidyl ether, phenol ethyleneoxideglycidyl ether, and lauryl alcohol ethyleneoxide glycidyl ether or thelike. In addition to the above, mentioned as examples are: awater-soluble epoxy resin obtained by reacting a carboxy compound, whichis obtained through a reaction between a polyoxyethylene polyol compoundand an anhydride compound, and an epoxy resin having two or more epoxygroups in its molecules; and a self-emulsifiable epoxy resin compositionobtained by mixing the water-soluble epoxy resin and the epoxy resinhaving two or more epoxy groups in its molecules. Such resins can beobtained for example under the tradenames of XZ 92533.00, XZ 92598.00,and XZ 92446.00 from The Dow Chemical Company.

Examples of the anhydride compound include, but are not limited to,aromatic anhydrides such as phthalic anhydride, trimellitic anhydride,and pyromellitic anhydride; and cyclic aliphatic anhydrides such asmaleic anhydride, succinic anhydride, tetrahydrophthalic anhydride,methyl tetrahydrophthalic anhydride, methyl nadic anhydride, alkenylsuccinic anhydride, hexahydrophthalic anhydride, and methylhexahydrophthalic anhydride. There is no limitation on the epoxy resinhaving two or more epoxy groups in its molecules, and all known epoxyresins with an epoxy functionality of greater or equal to two can beused. Examples are polyglycidyl ether obtained from epichlorohydrin anda polyhydric compound such as, phenol novolac, and cresol novolacbisphenol A, bisphenol F, bisphenol S, resorcinol, hydroquinone orcatechin; alkylene oxide-added bisphenol A; polyalcohols such aspolypropylene glycol, 1,6-hexanediol, trimethylol propane, glycerin,cyclohexanedimethanol; and polyglycidyl ester and polyglycidyl amine ofpolycarboxylic acids such as adipic acid, phthalic acid, dimer acid andthe like.

The crosslinker, e.g. an aqueous crosslinker, containing an isocyanategroup are, for example: polyisocyanate mainly containing at least onemember selected from the group consisting of an isocyanurategroup-containing polyisocyanate, an urethodione group-containingpolyisocyanate, an urethodione group/isocyanurate group containingpolyisocyanate, an urethane group containing polyisocyanate, anallophanate group containing polyisocyanate, a biuret group containingpolyisocyanate, a carbodiimide group containing polyisocyanate, and anuretodione group containing polyisocyanate, each of which contains1,6-hexamethylene diisocyanate and/or isophorone diisocyanate as a rawmaterial; and a self-emulsifiable polyisocyanate obtained by reacting ahydrophilic surfactant having at least one active hydrogen group whichcan react with an isocyanate group or polyethylene ether alcoholcontaining at least three poly-ethylene oxide units with fatty acidester in which the sum of the number of carbons of fatty acid and ahydroxyl containing compound as raw materials is 8 or more and which hasat least one active hydrogen group which can react with an isocyanategroup. In addition to the above, an urethane group-containingpolyisocyanate obtained by reaction between1,6-hexamethylenediisocyanate and/or an isophorone diisocyanate and anactive hydrogen group-containing compound or polyisocyanate obtained byan allophanatization reaction, carbodiimidization reaction,uretodionization reaction, and biuretization reaction of thesediisocyanate compounds can be mentioned.

Examples of the crosslinker derived from aldehyde are water-dispersed orwater-dispersible or water-soluble phenol formaldehyde resins, aminoformaldehyde resins or combinations thereof.

Phenol formaldehyde crosslinkers include, but are not limited to,reaction products of aldehydes with phenols. Examples of aldehdydesinclude, but are not limited to, formaldehyde and acetaldehyde. Variousphenols can be used such as, but not limited to, phenol, cresol,p-phenylphenol, p-tert-butylphenol, p-tert-amylphenol,cyclopentylphenol, cresylic acid, bisphenol-A, bisphenol-F, and thelike, and combinations thereof. Also acid functional phenols could beused in making phenol formaldehyde resins. The crosslinkers can beunetherified or etherified with alcohols or polyols. These phenolformaldehyde resins may be soluble or self-emulsifiable in water or canbe stabilized by use of colloid stabilizers such as polyvinyl alcohol.

Amino formaldehyde crosslinkers include, but are not limited to,reaction products of aldehydes with amino or amido group containingmolecules. Examples of aldehydes include, but are not limited to,formaldehyde and acetaldehyde. Various amino or amido group containingmolecules can be used such as, but not limited to, urea, melamine,benzoguanamine, acetoguanamine, glycoluril and the like. Suitable aminocrosslinking resins include melamine-formaldehyde, urea-formaldehyde,benzoguanamine-formaldehyde, acetoguanamine-formaldehyde,glycoluril-formaldehyde resins. Also the methylol groups of an aminoformaldehyde resin can be partially or fully etherified with at leastone of the groups of monohydric aliphatic alcohols such as methanoland/or n-butanol. These amino formaldehyde resins may be soluble orself-emulsifiable in water or can be stabilized by use of colloidstabilizers such as polyvinyl alcohol can be used to stabilize the aminoformaldehyde dispersions.

Examples of commercially available amino-formaldehyde resins which arewater soluble or water dispersible and useful for the instant purposeinclude Cymel™ 301, Cymel™ 303, Cymel™ 370, and Cymel™ 373, from CytecSurface Specialties. Other aldehydes used to react with the aminocompound to form the resinous material are crotonic aldehyde, acrolein,or compounds which generate aldehydes, such as hexamethylene-tetramine,paraldehyde, and the like.

A number of embodiments provide that the crosslinker comprises ahydroxyalkyl amide. The crosslinkers can be water-soluble and beemployed to crosslink carboxylic acid. Examples of hydroxyalkyl amidesinclude, but are not limited to, Bis(N,N′-dihydroxyethyl)adipamide andthe like. Such compounds are commercially available under the tradenameof PRIMID™ crosslinker resins from EMS-PRIMID in Switzerland, forexample PRIMID™ XL-522, PRIMID™ SF-4510 and PRIMID™ QM-1260.

A number of embodiments provide that one or more crosslinkers may beadded to the aqueous dispersion as part of the aqueous dispersionformulation process; or in the alternative, a number of embodimentsprovide that one or more crosslinkers may be added to the coatingcomposition, e.g. the crosslinker may be added to the aqueous dispersionafter the dispersion formulation process.

Depending on the coating application, e.g., the type of food and/orbeverage that is to be contained in a coated container, and on desiredcoating properties it may be beneficial to combine several crosslinkers.Also, for some coating applications some crosslinkers may be more suitedthan others. Some crosslinkers may not be suited for particular coatingapplications. Some crosslinkers may be employed with the addition ofcatalysts for curing. Crosslinkers can help to build thermoset networkswhich are indicated by higher values of MEK Double Rubs, e.g., ascompared to an identical coating composition not containing thecrosslinker.

Embodiments of the present disclosure provide that the coatingcomposition can include an antioxidant. The antioxidant can be from0.001 weight percent to 0.1 weight percent of the coating compositionbased on the total weight of the coating composition. All individualvalues and subranges from 0.001 to 0.1 weight percent are includedherein and disclosed herein; for example, the antioxidant can be from alower limit of 0.001, 0.002, or 0.005, to an upper limit of 0.1, 0.09,or 0.07 weight percent of the coating composition based on the totalweight of the coating composition. For example, the antioxidant can from0.001 to 0.1 weight percent, 0.002 to 0.09 weight percent, or 0.005 to0.07 weight percent of the coating composition based on the total weightof the coating composition. The antioxidant can help to protect theaqueous dispersion, e.g., at high cure temperatures. Embodiments of thepresent disclosure provide that the antioxidant comprises a hinderedphenolic. An example of the hindered phenolic includes, but is notlimited to, pentaerythritoltetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, which iscommercially available as IRGANOX™ 1010, available from Ciba.

Embodiments of the present disclosure provide that the coatingcomposition can include an additive. Examples of the additive include,but are not limited to, fillers, catalysts, wetting agents, defoamers,flow agents, release agents, slip agents, anti-blocking agents,additives to mask sulfur staining, pigment wetting/dispersion agents,anti-settling agents, UV stabilizers, adhesion promoters, corrosioninhibitors, pigments, e.g. titanium dioxide, mica, calcium carbonate,barium sulfate, silica, zinc oxide, milled glass, aluminum trihydrate,talc, antimony trioxide, fly ash, and clay or the like; optionally oneor more solvents, e.g. glycols, glycol ether,2,2,4-trimethyl-1,3-pentanediol monoisobutyrate, mineral spirits, andbenzoate esters or the like; optionally one or more dispersants, e.g.aminoalcohols, and polycarboxylates, optionally one or more defoamers,optionally one or more preservatives, e.g. biocides, mildewcides,fungicides, algaecides, and combinations thereof, optionally one or morethickeners, e.g. cellulosic based thickeners such as hydroxyethylcellulose, hydrophobically modified alkali soluble emulsions,hydrophobically modified ethoxylated urethane thickeners, andcombinations thereof, among others. Different amounts of the variousadditives may be utilized for different coating applications.

As mentioned, the coating compositions disclosed herein may be appliedto a substrate. Examples of the substrate include, but are not limitedto, beverage cans, food cans; aerosol containers such as those fornon-food products, e.g. hair spray, hair dye, or color spray lacquers;drums; kegs; pails; decorative tins; open trays; tubes; bottles;monoblocs; caps, lids such as thin aluminum foil based lids for yogurtand butter containers, or crown corks; closures for glass jars andbottles such as roll-on closures, vacuum closures, pilfer-proofclosures, easy peel lids for can closures, and easy open end orconventional ends for cans, among others. Cans, to which the coatingcompositions disclosed herein may be applied, can be 2 piece cans or 3piece cans. Beverage cans include, but are not limited to, beer cans,carbonated soft drink cans, energy drink cans, isotonic drink cans,water cans, juice cans, tea cans, coffee cans, milk cans, and the like.Food cans, include, but are not limited to, vegetable cans, fruit cans,meat cans, soup cans, ready meal cans, fish cans, edible oil cans, saucecans and the like. Such cans may have various shapes; for example, suchcan may have a cylindrical shape, cubical, spherical, semi-spherical,bottle shape, elongated cubical shape, shallow or tall shape, round orrectangular shape or other suitable shape, or a combination thereof.According to a number of embodiments, the substrate comprises a metal,e.g., a metal substrate. Examples of the metal include, but are notlimited to, aluminum and aluminum alloys, steel, electrolytic tinplatecold rolled low carbon mild steel, electrolytic chromium/chromium oxidecoated cold rolled low carbon mild steel, and other pre-treated steels.Pretreatment may include, but is not limited to, treatment withphosphoric acid, zirconium phosphate, chromium phosphate, and the likeas well as silanes for reasons such as primary corrosion protection andimproved adhesion. The metal substrate may comprise a sheet, strip or acoil. The substrate may be pre-coated with one or more pre-coatingcompositions. Such pre-coating compositions include, but are not limitedto, one or more resin binders, one or more resin crosslinkers, one ormore solvents, one or more additives, and one or more pigments. Examplesof resin binders include, but are not limited to, epoxy, polyester,polyvinyl chloride containing organosols/vinyls, phenolic, alkyd,oleoresin, acrylic resin, and the like. Examples crosslinkers include,but are not limited to, phenol-formaldehyde resins; amino-formaldehyderesins including but not limited to urea-formaldehyde, melamineformaldehyde, benzoguanamine formaldehyde; anhydride resins, blockedisocyanate resins and epoxy groups containing resins, including but notlimited to, epoxy resins, epoxy groups containing polyesters, acrylicresins, vinyl resins or the like. Examples of solvents and thinnersinclude, but are not limited to, glycol ethers, alcohols, aromatics,e.g. aromatic hydrocarbons, white spirit, branched ketones and esters.Examples of additives include, but are not limited to, catalysts,lubricants, wetting agents, defoamers, flow agents, release agents, slipagents, anti-blocking agents, additives to mask sulfur staining, pigmentwetting/dispersion agents, anti-settling agents, UV stabilizers,adhesion promoters. Pigments include, but are not limited to titaniumdioxide, zinc oxide, aluminum oxide, zinc and aluminum. The substratemay also be pre-coated with one or more pre-coated laminatecompositions. Such compositions may, for example, include polyethylene,polypropylene, or polyester compositions, and may be applied either as afilm via film lamination process or melt-extrusion coating process ontothe metal substrate.

The substrate may be formed via stamping, drawing, redrawing, wallironing, bending, beading, embossing, debossing, flanging, necking,stretching, blow-stretching and/or other suitable conventional methods.Such methods are known to those having ordinary skill in the art.According to a number of embodiments, the coating compositions may, forexample, be applied to the substrate, e.g. metal sheet or metal foil,and then the coated substrate may be formed into a coated article, e.g.,a container device or a coated closure device. According to a number ofembodiments, the substrate may be formed into a container, e.g., acontainer device or a closure device, and then the container device orthe closure device can be coated with the coating compositions to formthe coated article. The coating compositions may be applied by variousmethods; for example, via roller coating, spray coating, powder coating,dip coating, electrodeposition coating, printing, wash coating, flowcoating, draw down coating, and/or curtain coating. The coating, i.e.the coating composition applied to the substrate, may have a thicknessin the range of 0.01 micrometers (μm) to 2 millimeters (mm). Allindividual values and subranges from 0.01 μm to 2 mm are included hereinand disclosed herein; for example, the coating may have a thickness froma lower limit of 0.01 μm, 0.05 μm, or 1 μm, to an upper limit of 2 mm,1.5 mm, or 1 mm. For example, the coating may have a thickness 0.01 μmto 2 mm; 0.05 μm to 1.5 mm; or in the alternative, 0.1 μm to 1 mm.According to a number of embodiments, the coating may have a thicknessin a range of 5 μm to 50 μm.

The coating composition applied to the substrate may be cured, e.g., toform a cured coating. The curing process can comprise drying, e.g., airdrying, convection oven drying, hot air drying, and/or infrared ovendrying, among others. According to a number of embodiments, the curingcan include radiation cure, e.g. electron-beam cure. The coatingcompositions applied to the substrate may be cured at a temperature inthe range of 10° C. to 375° C. for a period of less than 60 minutes, forexample, less than 40 minutes, less than 30 minutes, less than 20minutes, less than 10 minutes, less than 5 minutes, less than 2 minutes,less than 1 minute, or less than 20 seconds. All individual values andsubranges from 10° C. to 375° C. are included herein and disclosedherein; for example, the coating compositions applied to the substratemay be cured at a temperature in the range of 15° C. to 260° C. for aperiod of less than 60 minutes, for example, less than 40 minutes, lessthan 20 minutes, less than 10 minutes, less than 5 minutes, less than 2minutes, or less than 1 minute, or in the alternative, the coatingcomposition applied to the substrate may be cured at a temperature inthe range of 15° C. to 235° C. for a period of less than 60 minutes, forexample, less than 40 minutes, less than 10 minutes, less than 5minutes, less than 2 minutes, or less than 1 minute. The cured coatingmay have a thickness in the range of 0.01 micrometers μm to 2millimeters mm. All individual values and subranges from 0.01 μm to 2 mmare included herein and disclosed herein; for example, the cured coatingmay have a thickness from a lower limit of 0.01 μm, 0.05 μm, or 1 μm, toan upper limit of 2 mm, 1.5 mm, or 1 mm. For example, the cured coatingmay have a thickness 0.01 μm to 2 mm; 0.05 μm to 1.5 mm; or in thealternative, 0.1 μm to 1 mm. According to a number of embodiments, thecured coating may have a thickness in a range of 1 μm to 50 μm.

As mentioned, the coating compositions disclosed herein, which includean abrasion reducing composition, are able to provide a continuous curedcoating with a desirable coefficient of friction, e.g., as indicated bya reduced abrasion value. For example, a continuous cured coating can byformed by curable composition having a reduced abrasion value ascompared to a non-continuous cured coating formed from a compositionhaving a relatively higher abrasion value. The continuous cured coatingidentified by an appearance rating determined by visual inspection, e.g.with magnification. Coefficient of friction ratings for cured coatingscan be determined, for example, via lateral dragging of a steel ballacross the cured coating and determining a ratio of the lateralfrictional force for a respective sample to the normal force from thesteel ball. Continuous cured coatings having a desirable coefficient offriction are useful for some coating applications.

EXAMPLES

In the Examples, various terms and designations for materials were usedincluding, for example, the following:

Polyolefin (polypropylene, 6D43 polypropylene, available from The DowChemical Company), stabilizing agent (ethylene- acrylic acid copolymer,PRIMACOR™ 5980i, available from the Dow Chemical Company), compatiblizer(propylene-maleic anhydride graft copolymer, LICOCENE® 6452, availablefrom Clariant), antioxidant (pentaerythritoltetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate), IRGANOX™1010, available from Ciba), solvent (diethylene glycol monoethyl ether,available from Acros Organics), base (dimethylethanolamine, availablefrom Huntsman), crosslinker (hydroxyalkyl amide, Primid® QM-1260,available from EMS-GRILTECH), solvent (ethylene glycol, available fromMEGlobal), polyether-polyester modified hydroxy functional polysiloxane(BYK® 375 [25 weight percent polyether-polyester modified hydroxyfunctional polysiloxane, 75 weight percent dipropylene glycol monomethylether], available from BYK), wax (carnauba wax, AQUACER® 1547 [35 weightpercent wax, 65 weight percent water], available from BYK), wax(Fischer-Tropsch wax, SLIP-AYD® SL 404 [18 weight percent wax, 82 weightpercent 2-Butoxyethanol], available from Elementis), lubricant(polytetrafluoroethylene, FLUORO A [100 weight percentpolytetrafluoroethylene], available from Shamrock Technologies),lubricant (hydroxy functional polysiloxane, 163 Additive [100 weightpercent hydroxy functional polysiloxane], available from DOW CORNING®),lubricant (polydimethylsiloxane, 200 Additive [100 weight percentpolydimethylsiloxane], available from DOW CORNING®).

Example 1 Coating Composition

A coating composition, Example 1, was prepared by, as follows. Anaqueous dispersion was prepared as follows. Polypropylene added at 212grams per minute, PRIMACOR™ 5980i, added at 68 grams per minute, andLICOCENE® 6452 added at 23 grams per minute were fed into a 25 mmdiameter twin screw extruder by a controlled rate feeder where they wereforwarded and melted. The extruder temperature profile was ramped up toapproximately 160° C. Water and base were mixed together and fed to theextruder at 41 grams per minute as a neutralizing agent. Dilution waterwas fed via two separate pumps to two locations into a dilution zone ofthe extruder. The extruder temperature profile was cooled back down to atemperature below 100° C. by the end of the extruder. The extruder speedwas approximately 1200 rpm. At the extruder outlet, a backpressureregulator was used to adjust to a suitable pressure inside the extruderbarrel to reduce steam formation. The aqueous dispersion was filteredthrough a 200 micron filter. The aqueous dispersion had a solids contentof 47 weight percent and a mean particle size of 1.1 microns.Thereafter, the aqueous dispersion was manually stirred and filtered (50micron filter) and added to a first container to provide a filteredaqueous dispersion (351.54 grams). PRIMID® QM-1260 (2.523 grams) wasadded to the contents of the first container while stirring at 375rotations per minute with a Cowles blade. Base (0.313 grams) that hadbeen mixed into water (104.18 grams) was added to the contents of thefirst container over an interval of approximately one minute while thestirring continued. Ethylene glycol (17.42 grams) was added to thecontents of the first container over an interval of approximately oneminute while the stirring continued. IRGANOX™ 1010 (0.17 grams) that hadbeen dissolved in diethylene glycol monoethyl ether (17.42 grams) wasadded to the contents of the first container over an interval ofapproximately one minute while the stirring continued. The contents ofthe first container were covered and stirred for 15 minutes. A 30 gramaliquot was taken from the first container and then poured into a secondcontainer and BYK® 375 (0.024 grams) and AQUACER® 1547 (0.30 grams) wereadded to the contents of the second container while the stirringcontinued to provide Example 1. Example 1 was covered and stirred at 450rotations per minute for 15 minutes.

Example 2 Coating Composition

A coating composition, Example 2, was prepared as follows. Example 2 wasprepared as Example 1 with the change that BYK® 375 (0.012 grams) wasused in place of the BYK® 375 (0.024 grams (from Example 1)) andAQUACER® 1547 (0.15 grams) was used in place of the AQUACER® 1547 (0.15grams (from Example 1)).

Example 3 Coating Composition

A coating composition, Example 3, was prepared as follows. Example 3 wasprepared as Example 1 with the change that AQUACER® 1547 (0.15 grams)was used in place of the AQUACER® 1547 (0.30 grams (from Example 1)).

Example 4 Coating Composition

A coating composition, Example 4, was prepared as follows. Example 4 wasprepared as Example 1 with the change that filtered aqueous dispersion(117.18 grams) was used in place of the filtered aqueous dispersion(351.54 grams), PRIMID® QM-1260 (0.841 grams) was used in place of thePRIMID® QM-1260 (2.523 grams), base (0.104 grams) was used in place ofthe base (0.313 grams), water (34.73 grams) was used in place of thewater (104.18 grams), ethylene glycol (5.805 grams) was used in place ofthe ethylene glycol (17.42 grams), IRGANOX™ 1010 (0.055 grams) was usedin place of IRGANOX™ 1010 (0.17 grams), diethylene glycol monoethylether (5.805 grams) was used in place of the diethylene glycol monoethylether (17.42 grams), a 10 gram aliquot was used in place of the 30 gramaliquot, BYK® 375 (0.004 grams) was used in place of the BYK® 375 (0.024grams (from Example 1)) and SLIP-AYD® SL 404 (0.1 grams) was used inplace of the AQUACER® 1547.

Example 5 Coating Composition

A coating composition, Example 5, was prepared as follows. Example 5 wasprepared as Example 4 with the change that SLIP-AYD® SL 404 (0.3 grams)was used in place of SLIP-AYD® SL 404 (0.1 grams).

Example 6 Coating Composition

A coating composition, Example 6, was prepared as follows. Example 6 wasprepared as Example 4 with the change that SLIP-AYD® SL 404 (0.3 grams)was used in place of the BYK® 375 and the AQUACER® 1547.

Example 7 Coating Composition

A coating composition, Example 7, was prepared as follows. Example 7 wasprepared as Example 4 with the change that SLIP-AYD® SL 404 (0.1 grams)was used in place of the BYK® 375 and the AQUACER® 1547.

Comparative Example A

Comparative Example A was prepared as follows. Comparative Example A wasprepared as Example 1 with the change that filtered aqueous dispersion(97.62 grams) was used in place of the filtered aqueous dispersion(351.54 grams), PRIMID® QM-1260 (0.706 grams) was used in place of thePRIMID® QM-1260 (2.523 grams), base (0.058 grams) was used in place ofthe base (0.313 grams), water (19.29 grams) was used in place of thewater (104.18 grams), ethylene glycol (9.68 grams) was used in place ofthe ethylene glycol (17.42 grams), IRGANOX™ 1010 (0.045 grams) was usedin place of IRGANOX™ 1010 (0.17 grams), diethylene glycol monoethylether (9.68 grams) was used in place of the diethylene glycol monoethylether (17.42 grams), a 10 gram aliquot was used in place of the 30 gramaliquot, and FLUORO A (0.05 grams) was used in place of the BYK® 375 andAQUACER® 1547.

Comparative Example B

Comparative Example B was prepared as follows. Comparative Example B wasprepared as Example 1 with the change that filtered aqueous dispersion(45.56 grams) was used in place of the filtered aqueous dispersion(351.54 grams), PRIMID® QM-1260 (0.329 grams) was used in place of thePRIMID® QM-1260 (2.523 grams), base (0.041 grams) was used in place ofthe base (0.313 grams), water (13.54 grams) was used in place of thewater (104.18 grams), ethylene glycol (2.24 grams) was used in place ofthe ethylene glycol (17.42 grams), IRGANOX™ 1010 (0.021 grams) was usedin place of IRGANOX™ 1010 (0.17 grams), diethylene glycol monoethylether (2.24 grams) was used in place of the diethylene glycol monoethylether (17.42 grams), a 10 gram aliquot was used in place of the 30 gramaliquot, and FLUORO A (0.05 grams) was used in place of the BYK® 375 andAQUACER® 1547.

Comparative Example C

Comparative Example C was prepared as follows. Comparative Example C wasprepared as Comparative Example A with the change that 163 Additive(0.05 grams) was used in place of the FLUORO A (0.05 grams).

Comparative Example D

Comparative Example D was prepared as follows. Comparative Example D wasprepared as Comparative Example A with the change that 200 Additive(0.05 grams) was used in place of the FLUORO A (0.05 grams).

Comparative Example E

Comparative Example E was prepared as follows. Comparative Example E wasprepared as Example 1 with the change that BYK® 375 (0.395 grams) wasadded to the contents (493.56 grams) of the first container rather thantaking a 30 gram aliquot from the first container and then adding BYK®375 and AQUACER® 1547.

Comparative Example F

Comparative Example F was prepared as follows. Comparative Example F wasprepared as Comparative Example E with the change that AQUACER® 1547(9.873 grams) was used in place of the BYK® 375.

Example 8 Coated Article

A coated article, Example 9, was prepared as follows. Aluminum panels(can stock clean aluminum measuring 0.009×4″×12″ from All Foils), werecleaned with acetone, and then dried. Approximately 12 hours afterExample 1 was prepared, Example 1 (approximately 3 grams) was applied tothe aluminum panel via a #13 wirewound drawdown bar to coat (20 micronsto 30 microns wet coating thickness) a surface of the aluminum panel toprovide Example 8.

Examples 9-14 Coated Articles

Coated articles, Examples 9-14, were prepared as follows. Examples 9-14were prepared as Example 8 with the change that Examples 2-7 wererespectively used in place Example 1.

Comparative Examples G-L

Comparative Examples G-L were prepared as follows. Comparative ExamplesG-L were prepared as Example 8 with the change that Comparative ExamplesG-L were respectively used in place Example 1.

Example 15 Coated Article with Cured Coating

A coated article with a cured coating, Example 15, was prepared asfollows. Example 8 was placed in a 295° C. convention oven forapproximately 25 seconds to cure the coating composition and provideExample 15.

Examples 16-21 Coated Articles with Cured Coatings

Coated articles with cured coatings, Examples 16-21, were prepared asfollows. Examples 16-21 were prepared as Example 15 with the change thatExamples 9-14 were respectively used in place Example 8.

Comparative Examples M-R

Comparative Examples M-R were prepared as follows. Comparative ExamplesM-R were prepared as Example 15 with the change that ComparativeExamples G-L were respectively used in place of Example 8.

Coefficient of friction ratings for Examples 15-21 and ComparativeExamples M-R were determined by respectively fixing each of Examples15-21 and Comparative Examples M-R in horizontal position such that thecured coatings faced upward. A steel ball, having a 0.25 inch diameter,was placed respectively on the cured coatings of each of Examples 15-21and Comparative Examples M-R with a normal force of 0.5 newtons. Thesteel ball was dragged laterally across the cured coatings of each ofExamples 15-21 and Comparative Examples M-R to measure a lateralfictional force. Coefficient of friction ratings for Examples 15-21 andComparative Examples M-R are defined as a ratio of the lateralfrictional force for a respective sample to the normal force.Coefficient of friction ratings are reported in Table 1.

Appearance ratings for Examples 15-21 and Comparative Examples M-R weredetermined by visual inspection with 10× magnification according to acontinuous qualitative scale, whereby an appearance rating of “0”indicated a non-continuous cured coating with prominent holes in thecured coating, exposed metal, extensive surface roughness, and/orextensive discoloration; an appearance rating of “1” indicated acontinuous cured coating, some surface roughness, and/or somediscoloration; and an appearance rating of “2” indicated a smoothcontinuous coating having no visible defects. Appearance ratings arereported in Table 1.

Continuous cured coatings, e.g., cured coatings with an appearancerating of 1.0 or greater, having a reduced abrasion value, which may beindicated by a desirable coefficient of friction, e.g., a coefficient offriction rating of 0.15 or less, are useful for some coatingapplications.

TABLE 1 Coefficient of Appearance friction rating rating (unit less)(unit less) Example 15 0.08 1.5 Example 16 0.12 2.0 Example 17 0.11 2.0Example 18 0.07 2.0 Example 19 0.06 2.0 Example 20 0.10 2.0 Example 210.14 2.0 Comparative Example M 0.16 0.25 Comparative Example N 0.31 0.5Comparative Example O 0.40 0.0 Comparative Example P 0.40 0.0Comparative Example Q 0.09 0.5 Comparative Example R 0.20 2.0

The data in Table 1 show that each of Examples 15-21 was a continuouscured coating. Additionally, the data in Table 1 show that each ofExamples 15-21 had coefficient of friction rating of 0.15 or less,indicating a reduced abrasion value. The data in Table 1 show that eachof Examples 15-21 are useful for some coating applications because eachof Examples 15-21 had a coefficient of friction rating of 0.15 or lessand an appearance rating of 1.5 or greater.

The data in Table 1 show that Comparative Examples M-P and R each had acoefficient of friction rating greater than 0.15. Additionally, the datain Table 1 show that Comparative Examples M-Q each had an appearancerating of less than 1.0 Comparative Example Q did have a coefficient offriction rating 0.09; however Comparative Example Q was not a continuouscured coating, as evidenced by the appearance rating of 0.5. ComparativeExample R was a continuous cured coating, as evidenced by the appearancerating of 2; however Comparative Example R did not have a coefficient offriction rating of 0.15 or less.

The data in Table 1 show that each of Examples 15-21 were improvedcontinuous cured coatings as compared to each of Comparative ExamplesM-R.

What is claimed:
 1. A coated article comprising a substrate and acoating on the substrate, wherein the coating includes the coatingcomposition comprises: from 50 to 85 percent of an aqueous dispersionbased on a total weight of the coating composition, wherein the aqueousdispersion comprises a melt blending product of (a) a base polymercomprising at least one polyolefin, (b) a polymeric stabilizing agent,and (c) a compatiblizer, wherein the aqueous dispersion has a solidcontent from 15 weight percent to 70 weight percent based on a totalweight of the aqueous dispersion, the solid content comprises from 50 to85 percent by weight of the base polymer based on a total weight of thesolids content, from 10 to 35 percent by weight of the stabilizing agentbased on the total weight of the solids content, and from 2 to 15percent by weight of the compatiblizer based on the total weight of thesolids content; an abrasion reducing composition comprising a hydroxyfunctional polysiloxane that is from 0.01 weight percent to 0.10 weightpercent of the coating composition based on the total weight of thecoating composition; a solvent, wherein the solvent is from 3 weightpercent to 20 weight percent of the coating composition based on thetotal weight of the coating composition; a basic water compositioncomprising from 90 to 99.99 percent by weight of the water based on atotal weight of the basic water composition and from 0.01 percent to 10percent by weight of a base based on the total weight of the basic watercomposition, wherein the basic water composition is from 10 weightpercent to 25 weight percent of the coating composition based on thetotal weight of the coating composition; and a crosslinker, wherein thecrosslinker is from 0.01 weight percent to 40 weight percent of thecoating composition based on the total weight of the coatingcomposition.
 2. The coated article of claim 1, wherein the substrate isa metal substrate.
 3. The coated article of claim 1, wherein the hydroxyfunctional polysiloxane is polyether modified, polyester modified, orpolyether-polyester modified.
 4. The coated article of claim 1, whereinthe hydroxy functional polysiloxane has a hydroxyl equivalent weight of500 to 2000 grams per hydroxyl equivalent.
 5. The coated article ofclaim 1, wherein the at least one polyolefin comprises polypropylene. 6.The coated article of claim 1, wherein the solvent is selected from thegroup of ethylene glycol, diethylene glycol monoethyl ether, dipropyleneglycol dimethyl ether, propylene glycol methyl ether, ethanol,dipropylene glycol methyl ether, and combinations thereof.
 7. The coatedarticle of claim 1, wherein the crosslinker is a hydroxyalkyl amide. 8.The coated article of claim 1, wherein the stabilizing agent is selectedfrom the group of ethylene-acrylic acid copolymer, ethylene-methacrylicacid copolymer, and combinations thereof.
 9. The coated article of claim1, wherein the compatiblizer comprises a maleic anhydride graftedpolypropylene polymer.
 10. The coated article of claim 1, where thecoating composition is cured to form a cured coating on the substrate.11. A coated article comprising a substrate and a coating on thesubstrate, wherein the coating includes the coating compositioncomprises: from 50 to 85 percent of an aqueous dispersion based on atotal weight of the coating composition, wherein the aqueous dispersioncomprises a melt blending product of (a) a base polymer comprising atleast one polyolefin, (b) a polymeric stabilizing agent, and (c) acompatiblizer, wherein the aqueous dispersion has a solid content from15 weight percent to 70 weight percent based on a total weight of theaqueous dispersion, the solid content comprises from 50 to 85 percent byweight of the base polymer based on a total weight of the solidscontent, from 10 to 35 percent by weight of the stabilizing agent basedon the total weight of the solids content, and from 2 to 15 percent byweight of the compatiblizer based on the total weight of the solidscontent; an abrasion reducing composition comprising a Fischer-Tropschwax that is from 0.01 weight percent to 1.5 weight percent of thecoating composition based on the total weight of the coatingcomposition; a solvent, wherein the solvent is from 3 weight percent to20 weight percent of the coating composition based on the total weightof the coating composition; a basic water composition comprising from 90to 99.99 percent by weight of the water based on a total weight of thebasic water composition and from 0.01 percent to 10 percent by weight ofa base based on the total weight of the basic water composition, whereinthe basic water composition is from 10 weight percent to 25 weightpercent of the coating composition based on the total weight of thecoating composition; and a crosslinker, wherein the crosslinker is from0.01 weight percent to 40 weight percent of the coating compositionbased on the total weight of the coating composition.
 12. The coatedarticle of claim 11, wherein the at least one polyolefin comprisespolypropylene.
 13. The coated article of claim 11, wherein the solventis selected from the group of ethylene glycol, diethylene glycolmonoethyl ether, dipropylene glycol dimethyl ether, propylene glycolmethyl ether, ethanol, dipropylene glycol methyl ether, and combinationsthereof.
 14. The coated article of claim 11, wherein the crosslinker isa hydroxyalkyl amide.
 15. The coated article of claim 11, wherein thestabilizing agent is selected from the group of ethylene-acrylic acidcopolymer, ethylene-methacrylic acid copolymer, and combinationsthereof.
 16. The coated article of claim 11, wherein the compatiblizercomprises a maleic anhydride grafted polypropylene polymer.
 17. Thecoated article of claim 11, where the coating composition is cured toform a cured coating on the substrate.